Cement, masonry, and steel construction



July 2, 1935. J J O"REll Y 2,006,650

CEMENT, MASONRY AND STEEL CONSTRUCTION Filed Jan. 9, 1929 4 Sheets-Sheet 1 QVI July 2, 1935. V J J OREILLY 2,006,650

CEMENT, MASONRY AND STEEL CONSTRUCTION Filed Jan. 9, 1929 4 Sheets-Sheet 2 Ill ll y 1935- J. J. OREILLY 2,006,650

CEMENT, MASONRY AND STEEL CONSTRUCTION Filed Jan. 9, 1929 4 Sheets-Sheet 3 July 2, 1935. J. J. OREILLY 2,006,650

CEMENT, MASONRY AND STEEL CONSTRUCTION Filed Jan. 9, 1 4 Sheets-Sheet 4 Patented July 2, 1935 UNITED s AT s CEMENT, MASONRY, AND STEEL CONSTRUCTION John James OReilly, Woodside, N. Y.

Application January 9,

11 Claims.

This invention relates to improved structural members and methods and has for its primary object to provide a very simple and serviceable means whereby said improved structural mem- 5 bers and methods may be applied to building construction to effect improved architectural and structural results with great economy.

It is a more particular object of my invention to provide large units of concrete, metals, stone, and wood and combinations thereof while providing for the field assembly of same by means of welding thus allowing for the completion of a building within a fraction of the time ordinarily required.

My invention also contemplates providing large standardized structural units of welded metal plates for easy assembly in the field by welding thus providing a structural frame which may be quickly completed with incidental finishing materials.

Another object of my invention is to provide a quick method of assembling large exterior wall units of partly prefireproofed metal with large standardized interior units of structural metal at a building site.

A still further object of my invention is to provide a quick and easy method of assembling large partly prefireproofed metal units with other incidental materials to complete a building structure.

' With the above and other objects in view the invention consists in the improved structural members and methods, and in the form, construction, and relative arrangement of the various parts as will be hereinafter more particularly described, illustrated in the accompanying drawings, and subsequently incorporated in the subjoined claims.

In the drawings in which I have shown various embodiments of my invention:

Figure 1 is an isometric diagram showing the improved structural members in conjunction with ordinary incidental materials.

Figure 2 is an isometric view of one half of an improved structural member.

Figure 3 is a full plan view of another im-' proved structural member.

Figure 4 is an elevation of still another type of improved structural member.

Figure 5 is a fragmentary side elevation of an embodiment of Figure 2.

Figure 6 is a horizontal sectional view of improved roof members.

Figure 7 is a plan of Figure 6.

Figure 8 is a detailed plan of partof Figure 7.

1929, Serial No. 331,308 7 Figure 9 .is a detailed plan of part of Figure 8.

Figure 10 is a vertical section, partly isometric at the upper part, showing the field assembly of animproved structural wall and floor member.

Figure 11 is a fragmentary vertical section .1 showing the field assembly of an improved struc= tural wall member, similar to the one shown in Figure 10, with an embodiment of the improved structural floor member.

Figure 12 is an isometric diagram showingthe location of builtin nailing or welding grounds for the erection of trim, etc., and also the metal framing employed in an improved structural member containing a full door opening.

Figure '13 is a fragmentary sectional view of the field assembly of an improved structural floor'member with an improved structural par-, tition member above and below, showing also builtin pipes and the method offield assembly used for same.

. Figure 14 is a section in plan of the side jamb of an opening, or a section in elevation of the head jamb of an opening, showing the method of applying trim in the shop or field.

Figure 15 is a fragmentary plan view showing the method used for framing out a pipe pocket for a field connection.

Figure 16 is a section through Figure 15 along the broken line A-A.

, Figure 17 is a fragmentary sectional view showing the method used for applying trim through theme of builtin welding grounds.-

Figure.18 is a sectional diagram of a com-' plete flightfof stairs.

Figure 19 is a plan view of a metalbacked wood stair tread face downward.

Figure 20 is a fragmentary detailed view of Figure 0 18.

Figure .21 is a face plan view of a strip 0 metalbacked parquet flooring.

Figure 22 is a fragmentary sectional detail of two improved structural members showing the method of field assembly and the method used for connecting electric conduits.

Figure 23 is a horizontal sectional view 'show* 45- ing the method of fastening metalbacked wood floors or trim by means of welding grounds.

Referring in detail tothe drawings, and more particularly to Figure 1, the symbol 40 indicates an ordinary sidewalk made in the usual manner. 501

4| indicates an open areaway made in the usual manner. 42 indicates a lefthand foundation footing, 43 indicates a cellar floor, and 44 indi-' cates a righthand foundation footing. Nothing new or patentable is claimed for the construc-' tion of the sidewalk, open areaway, foundation footings, or cellar floor, they are shown in the and M2 are improved structural fioor members,

' pleted and together with similar-roof units serve 0.1 containing the half stairwell ope'ningindicated by pt. (14, a6, a8, and allfindicate improved structural wall members containing the half door opening p3, the half window opening p1, and the full window openings p5 and p9- a5, all), and'a9 indicate improved structural interior partition members, containing the full door opening p4 and the half door opening p8.

al3, a, and al5 are improved structural attic members. al6 and allindicate improved structural roof members, al I containingthe half dormer opening plll.

In field assembly the unitsshown in the diagram Figure 1. areerected'in numerical order, asfollowsz" 1 .The foundation footings (42 and 44) having been fashioned in the'usual manner, and covered with a grout of fresh cement, the cellar wall unit (al) is'placed in'the position indicatediin Figure -1 and then-"the cellar wall unit (a2) is placed in position as shown.. .Similar units are put into position to complete the cellar walls.

When the cellar. walls have been. completed the floor unit (a3), is :placed in the position shown and similar units are put into position. to complete thefirstfioor. 1 J When the floor units have'been all .placed into position and. fastened the. wall unit (al), the partition unit (a5), and.the wall unit (0.6) are placed intothe. position indicated in Figure 1 and similar .units areput into position-to complete the first floor walls and interior. partitions. The. floor unit (a1) is placed in the position indicated and similar units used-to complete the second floor.

7 Then the second floor: exterior wall and. interior partition units (a8, a9, alll, and 'al I) are placed into position together with similar units to complete the second floor-work.

The attic floor unit (al2).-is1then 'placed in the position indicated in Figure l and similar units placed to complete the attic floor, after which the attic units (al3,'al4-,.and al5) are placed into theposition'indicated in. Figure land similarunits placed to..complete the interior .attic work. The roof units (alli .and all). are placed into the position indicated in Figurel after the rest of the structure has been comto complete the structure.

The field fastening; of all of thefimproved structural members is accomplished by' electric arc welding, and the details ofeach unit and the exact 'methcd of fastening .will-be more particularly described in. referring to the following drawings. H V

Figure 2 is a ofonev halfbf the improved structural floor. member 0.3, Figure 1, in

:which b4 indicates 'ametal floor joist, b2 indicates a header or cross framing member, b3

indicates a lateral brace, and W indicates welding wherever the metalplates comeintoexposed contact with each other.. The'interior partition unit (a9) and the attic units (al3 andialll are made in asimilar' manner, except that bl:

would indicate a partitionstud, I)? a sill or plate, and b3 would indicate a lateral brace..- The attic floor unit (all) is:likewise:made in;

stud, b2 8. sill or plate, 123 a lateral brace, and bi a header for framing out they half window opening p1.

Figure l is a detailed elevation of the improved structural wall member (a6) showing the method of framing around the full window open- The cellar wall units ,(al and a2) are constructed in a similar manner except that the. window openings (pl andpZ) are relatively smaller. The second floor wall unit (al I) is.exactly.similar toali. 1 .7 Figure 5 is a fragmentary side elevation .of the improved structural roof member (all), showing the. .mitering of the cross framing plate (M) to efiect a mitred contact at thepeak of the roof. all is otherwise similar to al as shown in Figure 3. alli is similarrto. all except that the framing out for the half dormer open-.- ing is omitted.

All of ,the above mentioned members are formed by welding ordinary metal plates gether wherever. the metal of one, plate comes into exposed contact with the metal of another plate. The field: assembly is likewise accomplished byweldingadjacent units to each otherin the relative position indicated in the diagram Figurel. we

Figures 6, 7, 8, and 9 indicate the fabrication and field assembly of roofing shingles also by welding.

In Figure-9, 20 indicates that portion. of an individual shingle exposed to the weather,- and 2| indicates that portionof an individual shingle not exposed or lapped by adjacentshingles.

Figure 8 indicates the shop assembly ofa plu-.

,rality of individual shingles to form a super-,

in the upper right hand corner as indicated-by supershingle pattern on a platform and welding V the individual shinglestogether fromthe back.

The individual shingles are of metal, preferably galavanized iron dippedinto' paint and other:

wise treated for varied colored, and textural effects before assembly. i I

Figures .6 andj7 indicate the field assembly of four supershingles; (20a/2la-22a-:-23a,) withthe ridge cap, :indicated by, 240, to complete one half of a roof. The other half of the roof is exactly similanexcept that dormer;openings may be left uncovered and no additional ridge cap is required. The ridge cap is a nar row supershingle bent at right angles as shown. The broken outline of an improved structural roof member, indicated by al I, is shown beneath the supershingles in Figure 7, and in the same figure 24c indicates a projecting eave. Figure 6 indicates clearly how the supershingles are placed into position for field welding, the lower one (20a) first, then 2| a, 22a, and 23a. in order. The ridge cap is not placed into position until the supershingles on the opposing pitch of the roof have been welded in place. The field welding of the supershingles is accomplished from underneath in the attic, and the ridge cap welding being exposed is carefully protected from the weather. It will be understood that metal other than galvanized iron may be used to form the supershingles, and that brazing or soldering may likewise be used for fastening purposes.

To obtain certain architectural, and economic results the improved structural members (a! to all, inclusive) may be (partly) prefireproofed before field assembly. The

: method of field welding for prefireproofed metal members is likewise described and covered in above mentioned application and nothing new is disclosed in this application for the process of arc welding through open joints in stonework.

.Figure 10 shows the method of assembly used in the field for a prefireproofed wall member (Kai) and the improved structural fioor member (11. Fp indicates the prefireproofing accomplished in the shop. W indicates field weld- In thelower half the welding is accomplished, as described in the previously mentioned application, through the open joints, indicated by WW. In the upper part of the figure the metal plate D2 is welded to the exposed wall studding (b4) in the field. I

Figure 11 shows the method used for assembling a prefireproofed wall member (Ka and a prefireproofed fioor member (Xa'l) by welding them together in the field as indicated at W.

Figure 12 indicates the location of builtin welding or nailing grounds for picture mouldings, trim around an opening, base, door saddles or sills, and floors. The framing of the improved structural interior partition member isalso clearly indicated. The symbol G indicates a welding ground.

Figure 14 shows in section the location and arrangement of the builtin grounds around a window or door opening and W indicates the field welding or shop welding which is accomplished through a hole in the trim as described hereinafter. T1 indicates a rabbeted jamb and T8 standing trim.

Figures 13, 15, and 16 refer to builtin piping, in which in indicates a length of pipe builtin a prefireproofed structural member. X341 and X40a Figure 15 indicate prefireproofed structural floor members, placed side by side .and welded together from above and below through open vertical joints similar to the open horizontal joints indicated at the lower part of Figure 10. WAB indicates field welding along the line of the adjacent floor joists both'above and below the plane of the fragmentary view shown in Figure 15. In fabricating the structural members X3a and X40a the continuity of the floor joists is broken as shown. and spliced with the splice joists b6 thus forming a pocket p|2 when the adjacent joists are brought together in the process of field assembly. A length structural,

of pipe is indicatedby 1p in each fioor member at right angles to the floor-joists and passing through a hole provided in the splice plates b6.

Field assembly of the structural floor members brings the open ends of the pipes directly opposite each other and they are welded together, or the pocket p12 is filled withlead to caulk, the joint, or in the case of brass pipe brazing is used to make a tight joint.

Figure 16 is a sectional view of Figure 15 along the broken line A-A, and shows the pipe pocket (1H2) more clearly. b1 indicates a small platewhich is welded to the bottom of the pocket to permit caulking without waste. Figure l3 indicates the method used for exposing the ends of builtin pipes for a cross connection. X3a is a prefireproofed floor member, Xiia is a .prefireproofed partition member above, and X2za indicates the same below. In field assembly the open ends of the builtin pipes (1p) are brought directly over each other and weldedt'ogether through the open joints as indicated by W. It will be noted that the pocket (pl2), as indicated in Figures 15 and 16, will serve as an ideal expansion fitting for heating pipes. When the ends of the pipes which enter the pocket are kept slightly apart, and notfastened together, expansion and contraction is automatically taken care of by the vibration of the splice joists b6. In order to confine the contents" of heating pipes within the pocket (pIZ) a plate similar to bl is fastened to the top of said pocket and the entire pocket welded air tight.

Through leaving open ends of pipe projecting thru the prefireproofed members as indicated in Figure 13 it is a simple matter to connect other pipes thereto simply by welding close to the face of the unit and covering the weld with an escutcheon. In this manner the exposed piping may be extended to the boiler, radiators, plumbing fixtures, etc.

Figure 19 shows a metal plate, indicated by m2, with six holes punched through same as indicated by 7L3. An ordinary wooden stair tread is placed face downward on a platform and a metal plate similar to that shown in Figure 19 is placed over the back of same and fastened thereto by means of wood screws passed through the. holes k3. A stair riser of metalbacked wood is fashioned in a similar manner, likewise. a wall stringer, except that the wood for the wall stringer is profiled to follow the line of the tread and the riser in the assembled stair as shown in Figure 20. In Figure 18-8 indi-' cates a Wall stringer, S2 a stair tread, S3 a stair riser, and S4 indicates a base stringer. Figure 20 shows a detailed view of the shop assembly of an entire stair, m4 indicates the exposed woodwork and m2 the concealed metal work. W indicates the shop welding of treads to risers. W5 indicates the shop welding of the treads and risers to the wall stringer. 7L2 indicates a welding hole in the concealed part of the stair for fastening the wall stringer to a welding ground builtin the stairwell partition. It will be under stood that units of marble may be backed with metal by boring holes in the backof the marble and filling same with fresh cement before inserting the screws through the metal back, and likewise that the complete stair may be formed of welded metal plates and then covered on the exposed portions with welded wire lath and plastic finishing materials. The complete stair in any event is fabricated complete at the shop and installed as a complete unit in the field.-

the'effect of parquet, herringbone,-'etc.,

to the adjacent surfaces;

face.

Figure 21 is a face plan of a strip of; parquet flooring to the back of which is fastened a'metal sheet similar .to m2, Figure. 19. 712 indicates holes-which have been cut in the finished face of the flooring. to permit field welding to a built in ground. Figure 23 indicates the method used for welding steelbacked wood flooring ,toa builtin floor ground thru the hole h2. m2 indicates the metal backing, m8 a layer of paper, and m4 the wood flooring with thefalse joints, indicated by ,V2, cut into the surface of same to give The thimble TIZ. is used as a temporaryshield for the wood and paper during the process of. welding. .W indicates how the metal backing (m2) is'welded to the builtin floor ground indicated by Figure .17 indicates the method used for welding metal trim, in the shop or field, to a builtin ground (G). ,T'l indicates a fragment of metalv .builtin grounds are always welded to some part'- of the structural frame, such as b.4-..-Fig. 17.

' When the field Welding is completed allwelding points are filled with materials and matched Figure 22 indicates the method used for splic-J ing lengths of electric conduit which are built-in the various prefireproofed members at the shop. The left hand fioormember, indicated by X3a, and the right hand floor'member, indicated by X40a, are to be placed together and welded to' each other throughthe open joints so formed as indicated by WW.. The flexible conduit, indicated by hr, and thejunction box, indicated by Jb, are first welded together. as indicated by W, and when the two units '(X3a and XflOa) are brought together for welding the junction box and the excess conduit arepla'ced in the recess surfaces are finished at the shop with colored texturedmonolithic facings as providedin the hereinbefore mentioned pending application. In the field the joints arepointed or filled with similar materials to provide an unbrokensur- When the field weldinghas been completed, and the boiler, radiators, plumbing fixtures, and lighting fixtures connected, and the welding points. covered or patched the house is completed. No exterior or interior painting is required, as owing to the method and the exactness thereof, even the doors and the window frames and sash, whether of metal orof wood, are made to an exact size andshop finished.

It will readily be seenfrom the foregoing de- 'scription considered in connection withthe ac-.

companying drawings that the construction, and

- methods and manner of use of the several il-- lustrated embodiments will be clearlyand fully understood. In View of the simplicity of the improved structural members and the methods 7 involved and their architectural, structural, and

economic importance they will be of great utility inthe construction of all typesof structures; I havedisclosed herein various formsof my im-,- proved structural members and the methods involved which I consider of, themost practical importance. Nevertheless'itis to be, understood that the invention, in view .of the wide scope of architectural and structural requirements; may alsobe exemplified in numerous other alternative constructions, andI, therefore reserve the privilege of adopting allsuch legitimate changes as may be fairly embodied within the spirit and scope of theinvention as claimed." 7 j r 1. A building structure comprising "an assembly of individual units arranged and disposed in precise architectural and structural relation to. form the encloseduseable spaces of the, said structure, certain of the aforesaid units containing each'awelding band with spacedsupporting members fastened thereto, also factory applied surfacing materials on two of its opposite architectural "surfaces concealing afield connected piping system extended for, service throughout thebuilding, reciprocal lateral support of the aforesaid welding band and. the spaced supporting members fastened thereto by otherynecessary, parts, of the structure in lieu,

of their being as formerly specially shaped .in the shop for self bracing laterally, 'and'a welded continuity of. the aforesaid units and other necessary parts providing aimaximum of reciprocal supportfor a' minimum of material outla -v 2. Abuilding' unit comprising a; welding band with spaced metal plate supporting members welded thereto, surfacing materials enclosing piping concealed in the interior of the said unit, offsetsfin the aforesaid welding band exposing for field fastening purposes the open ends of the aforesaid concealed piping, and means in. the unit for assembling samein welded continuity and precise architectural and, structural relation with other similar units in a building struc-' ture.

3. A building structure. comprising 'an-assem-' bly of individual units arranged and disposed in precise relation to form the useable spaces of the said structure, each of the aforesaid individ ual units'containing a separate structural frame comprising a welding band with spaced support ing members'zfastened thereto also factory applied surfacing materials enclosing field connected pipingconcealed in the interior of "the said unit, and a welded continuity of.all of =the aforesaid units throughout the structure.-

4.,A building structure comprisingan assembly of individual units arranged and disposedin precise architectural and structural relation to form the walls and the floors and the partitions and the roof of the said structure, certain'of the aforesaid units containing each a separate struc tural frame comprising a welding band with spaced supporting members fastened thereto also surfacing materials enclosing service piping and insulating materials concealed in the interior of the said units, and a welded continuity ofall of the aforesaidunits throughout the structure.

5. A'building structure comprising an assembly of individual units arranged and' disposed in precise architectural and structural relation to form the useable spaces of a complete dwelling, certain'of the aforesaid units containing each a separate-structural frame comprising a welding band forming a natural flatbed around the side and end edges of each of the said units for safe ultra speedy field: assembly purposes and spaced supporting members fastened to the interior of each of the said welding bands for the purpose of providing very large units for field setting having light and economical closely spaced supporting members, roofing bracing laterally supporting members of the structure in lieu of their being as formerly specially shaped in a form such as an angle for self bracing laterally, other features as hereinbefore newly disclosed optional, and a welded continuity of all of the aforesaid units and roofing and optional features throughout the finished dwelling.

6. A building structure comprising an assembly of individual units arranged and disposed in precise architectural and structural relation to form the useable spaces of the said structure, certain of the aforesaid units containing each a separate structural frame comprising a welding band forming a natural flat bed on the side and the end edges of each of the said units for safe ultra speedy field assembly purposes also spaced supporting members fastened to the interior of each of the said welding bands for the purpose of providing very large field units having closely spaced supporting members, flooring bracing laterally in push and pull manner supporting members of the structure in lieu of their being as formerly specially shaped in a form such as a channel for self bracing laterally, and a welded continuity of all of the aforesaid units throughout the structure.

7. A building structure comprising an assembly of individual units arranged and disposed in precise architectural and structural relation to form the useable spaces of the said structure, each of the aforesaid units continuing a separate structural frame exactly as disclosed hereinbefore, roofing and interior trim bracing laterally certain supporting members of the said structure, and a welded continuity of all of the aforesaid units and the roofing and the trim throughout the structure.

8. A building structure comprising an assembly of individual units arranged and disposed in precise architectural and structural relation to form the useable spaces of the said structure, each of the aforesaid units continuing a separate structural frame exactly as disclosed hereinbefore, sheathing and flooring bracing lateral- 1y certain supporting members of the said structure, and a welded continuity of all of the aforesaid units and the sheathing and flooring throughout the structure.

9. A building unit comprising metal plate headers forming two opposite ends of the said unit, a plurality of spaced metal plate supporting members fastened to the aforesaid metal plate headers to form a structural frame having cross framing members marking out such as window openings, two separate layers of surfacing materials forming an interior and an exterior wall surface for the main body of the .unit, and means in the unit for assembling same in precise architectural and structural relation with other units in a structure.

, 10. A building unit comprising a welding band with spaced joists or studs fastened thereto, two separate layers of cementitious or like materials moulded in the interior of the said Welding band, spaced metal re-inforcement embedded in the cementitious or like materials, one or more offsets in the aforesaid welding band exposing the ends of piping concealed in the unit, and means in the unit for assembling same in precise architectural and structural relation with other similar units in a building structure.

11. The relative steps involved in building a dwelling or the like which comprises the initial step of assembling individual sections above a previously prepared foundation in precise architectural and structural relation substantially as hereinbefore described with the outer surfaces of the said sections disposed in the proper relation to each other to form the enclosed living spaces of the said dwelling or the like, inserting an arc welding electrode between the outer surfaces of each two adjoining sections in turn as soon as they have been properly set and without injury to the said outer surfaces depositing welding beads collectively on the said sections to fasten them together rigidly just back of both outer surfaces of each of the said sections, caulking gas-tight with molten metal or the like around the ends of pipes exposed in exact relation to each other for the purpose between certain of the said sections, and finally filling with surfacing materials the crevices between the aforesaid sections to provide suitable surfaces therefor and to protect the welding deposits in the said crevices.

JOHN JAMES OREILLY. 

